Flexible Stackable Container With Heat-Sealed Rigid Corners
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Solution Overview
Problem
Current packaging solutions, such as VFFS bags, are not stackable due to lack of rigidity and do not retain shape after opening, while rigid containers are costly, non-recyclable, and inefficient in shipping and display due to shape and material constraints.
Innovation Solution
A flexible, stackable container formed from a sealed bag with a recloseable lid or flap, made from materials like polypropylene or ethyl vinyl alcohol, designed to be recyclable and biodegradable, with a quad seal package configuration that allows for efficient stacking and display.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If rigid packages are used, then stackability and shape retention are improved, but material cost and recyclability are worsened
Solution Approach 1:
The patent uses a flexible pouch made from thin film material that can be heat-sealed to form rigid corners and edges. This flexible shell approach provides the necessary structural support for stacking and shape retention while using minimal material, thereby reducing cost and improving recyclability compared to traditional rigid composite packages.
Solution Approach 2:
The patent changes the physical state of the flexible material through heat sealing, creating rigid corners and edges from flexible film. This parameter change (from flexible to rigid through thermal processing) allows the pouch to maintain its shape and be stackable without requiring expensive rigid composite materials throughout the entire structure.
2Stability of the object's composition
If rigid composite packages are used, then stackability is improved, but recyclability and environmental friendliness are worsened
Solution Approach 1:
The patent employs a flexible pouch constructed from heat-sealable film that forms rigid corners through sealing. This approach achieves stackability without using multi-layer composite materials that are difficult to recycle, thereby reducing environmental impact while maintaining the desired stability for stacking.
3Ease of manufacture
If round containers are used, then manufacturing is simplified, but shipping efficiency and display space are worsened
Solution Approach 1:
The patent transforms the symmetric round shape into an asymmetric form with rigid corners and flat sides created by heat sealing. This asymmetric configuration with defined edges and corners optimizes shipping efficiency and display space utilization while the flexible material remains simple to manufacture through heat sealing processes.
4Ease of manufacture
If round containers are used, then manufacturing is simplified, but shipping cost and environmental pollution are worsened
Solution Approach 1:
The patent creates an asymmetric container shape with rigid corners and flat sides through heat sealing of flexible film. This configuration maximizes shipping container space utilization, reducing the number of vehicles needed for transport and thereby decreasing shipping emissions and environmental pollution, while maintaining ease of manufacture through heat sealing.
5Ease of manufacture
If flexible bags without rigid structure are used, then material cost is reduced, but stackability is worsened
Solution Approach 1:
The patent uses a flexible pouch made from heat-sealable film that forms rigid corners and edges through localized heat sealing. This creates a hybrid structure where the majority of the material remains flexible and cost-effective, while the sealed corners provide the rigid structure necessary for stackability.
Solution Approach 2:
The patent applies localized parameter changes through heat sealing to transform flexible film into rigid corners and edges. This selective transformation maintains overall flexibility and low material cost while providing the structural support needed for stacking at critical locations.
Data Source
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AI summary
A flexible, stackable container for storing a quantity of a product may include a sealed package formed from a single sheet of film and retaining the quantity of the product disposed therein, and a lid fitment attached to a first side of the package. The first side of the package may have an outer first surface of the film and outwardly extending first corner seals formed in the film at the edges of the first side and surrounding the first side of the package. The package may also have a second side disposed opposite the first side and outwardly extending second corner seals formed in the film at the edges of the second side and surrounding the second side of the package. The lid fitment may include a base having a central opening and a lid having a complimentary shape to the base to form a seal therebetween when the lid is closed down onto the base. The base may be sealed to one of the first surface of the first side, to the first corner seals surrounding the first side, or to both, such that a portion of the first surface is accessible from the exterior of the container when the lid is separated from the base of the lid fitment.